Operating Manual, Model K/348012K Recovery/Recycling/Recharging Unit For R-12 and R-134a Refrigerants...1

Transcription

1 Operating Manual, Model K/348012K Recovery/Recycling/Recharging Unit For R-12 and R-134a Refrigerants...1

2 Refrigerant Recovery, Recycling and Recharging Station Series: K/348012K Refrigerants: R-12 and R-134a WARNING PRESSURIZED TANK CONTAINS LIQUID REFRIGERANT. OVERFILLING OF THE TANK MAY CAUSE VIOLENT EXPLOSION AND POSSIBLE INJURY OR DEATH. Refer to the instruction manual for tank specifications and ordering information. Do not recover refrigerants into a non-refillable storage container! Federal regulations require refrigerant to be transported only in containers meeting DOT spec. 4BW or DOT spec. 4BA. ALL HOSES MAY CONTAIN LIQUID REFRIGERANT UNDER PRESSURE. Contact with refrigerant may cause injury. Wear proper protective equipment, including safety goggles. Disconnect hoses with extreme caution. HIGH VOLTAGE ELECTRICITY INSIDE PANELS. RISK OF ELECTRICAL SHOCK. Disconnect power before servicing unit. Refer to the instruction manual. TO REDUCE THE RISK OF FIRE, avoid the use of an extension cord because the extension cord may overheat. However, if you must use an extension cord, use No. 14 AWG at the minimum and as short as possible. Do not use this equipment in the vicinity of spilled or open containers of gasoline or other flammable substances. Use this equipment in locations with mechanical ventilation that provides at least four air changes per hour or locate the equipment at least 18 inches above the floor. Make certain all safety devices are functioning properly before operating the unit. Before operating, read and follow the instructions and warnings in this manual. CAUTION: SHOULD BE OPERATED BY QUALIFIED PERSONNEL. Operator must be familiar with air conditioning and refrigeration systems, refrigerants and the dangers of pressurized components. Use only with R-12 or R-134a. This equipment is not designed for any other purpose than recovering, recycling or recharging refrigerants! Do not mix refrigerant types! ATTENTION! Ce réservoir sous pression contient du frigorigène liquide. S il est surchargé, ce réservoir peut exploser et causer des blessures ou la mort. ATTENTION. Débrancher avant la maintenance. ATTENTION. Pour réduire les risques d incendie, ne pas utiliser de cordon prolongateur de section inférieure à 14 AWG de facon à éviter la surchauffe du cordon. ATTENTION. Utiliser seulement du frigorigène R-134a. OPERATING NOTES At temperatures exceeding 120 o F / 49 o C, wait 10 minutes between recovery jobs. R-12 and R-134a WARNINGS! Use the Series K/348012K only with R-12 or R-134a! Cross-contamination with other refrigerant types will cause severe damage to the A/C system and to service tools and equipment. Do not mix refrigerant types through a system or in the same container! Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. To remove R-12 or R-134a from the A/C system, use service equipment certified to meet the requirements of SAE-J2210 (R-12 or R-134a recycling equipment). If accidental system discharge occurs, ventilate work area before resuming service. R-12 or HFC-134a service equipment or vehicle A/C systems should not be pressure tested or leak tested with compressed air. Some mixtures of air/hfc-r-12 /R-134a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing injury or property damage. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.

3 Table of Contents Introduction... 2 Glossary of Terms... 2 Set-Up Instructions... 4 Initial Set-Up... 4 Preparing the Vacuum Pump... 5 Operating Guidelines... 6 Using the Selection Menu... 6 Change Filter... 6 Recycle... 6 External Storage Vessel (ESV) Refill... 7 Vacuum Pump Hours... 8 Drier Recovered Lbs Basic/Advanced Prompts... 9 Auto Restart ON/OFF... 9 Selecting a Unit (Metric/English) Language Select Installation Routine/First Fill Using the Control Panel Keypad Functions Operating Instructions Operating Tips Recovering Refrigerant Evacuating the A/C System Replenishing A/C System Oil Recharging the A/C System Maintenance Instructions Replacing the Filter-Drier Changing the Vacuum Pump Oil Checking for Leaks Electrical Protection General Maintenance Replacement Parts List (348002K) Replacement Parts List (348012K) Flow Diagram Wiring Diagram Limited Warranty U.S. Patents: 4,523,897; 4,688,388 Re 33,212; 4,768,347; 4,805,416; 4,809,520; 4,878,356; 4,938,031; 5,005,369; 5,005,375; 5,038,578; 5,042,271; 5,209,653; 5,248,125 Australian Patent: 613,058 Canadian Patents: 1,311,621; 1,311,622; 2,012,620; 2,026,348 European Patent: Bl German Patent: Mexican Patent: OTHER U.S. AND FOREIGN PATENTS PENDING. Mfd. by Robinair, SPX Corporation, Montpelier, OH K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 1

4 Introduction This manual contains important safety procedures concerning the operation, use, and maintenance of this product. Failure to follow the instructions contained in this manual may result in serious injury. If you are unable to understand any of the contents of this manual, please bring it to the attention of your supervisor. Do not operate this equipment unless you have read and understood the contents of this manual. The K and K models are designed to be used on R-12 and R-134a vehicles. They are compatible with existing service equipment and standard service procedures. The K model is UL-listed. The K is CE approved. Both are single pass systems that meet the SAE specifications for recycled refrigerant. To validate your warranty, complete the warranty card attached to your unit and return it within ten days from date of purchase. GLOSSARY OF TERMS A/C System Unit External Storage Vessel Source Tank The air conditioning system being serviced. The refrigerant recovery/recycling/recharging unit. The refillable refrigerant storage vessel designed specifically for this unit. A disposable tank of new refrigerant used to refill the external storage vessel. Low Side Gauge High Side Gauge Low Side Gauge High Side Gauge Low Side Valve Low Side Valve High Side Valve Main Power Switch High Side Valve Selector Switch Keypad Diagram of the K Control Panel INST Robinair, SPX Corporation

5 Set-Up Instructions Diagram of Unit s Components External View Oil Injection Valves 2. R-134a Hoses Scales 4. Oil Injection Bottles Amp Breaker 6. 3 Amp Breaker Hose Holders 8. RJ45 Upgrade Port 9. Power Cord Receptacle 10. Quick Couplers R-12 Hoses 12. External Storage Vessel (ESV) 12 INST Diagram of Unit s Components Internal View 1. Relays 2. Compressor 3. Vacuum Pump 4. Filter 5. Manifold Block 6. Air Purge Assembly 7. Vacuum Pump Receptacle 8. Transformer 9. Fan 10. Oil Drain Bottle 11. Accummulator INST K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 3

6 Set-Up Instructions INITIAL SET-UP CAUTION! R-134a systems have special fittings (per SAE specifications) to avoid cross-contamination with R-12 systems. Do not attempt to adapt your unit for another refrigerant system failure will result! Read and follow all warnings at the beginning of this manual before operating the unit. CAUTION! Avoid the use of an extension cord because the extension cord may overheat. However, if you must use an extension cord, use a No. 14 AWG minimum and keep the cord as short as possible. IMPORTANT! You must press the MENU key to access all the functions. 1. Lock both front casters of the unit by stepping on the cam brake levers, plug the power cord into the power cord receptacle (Item 9 in the INST 0707 drawing on page 3). Turn on the MAIN POWER switch. 2. Press MENU. 3. Use the UP and DOWN arrows to select LANGUAGE SELECTION. Press ENTER. 4. Use the UP and DOWN arrows to scroll through the language options and press ENTER to select a language and exit LANGUAGE SELECTION. 5. Press MENU. Use the ARROW keys to go to SELECT AUTO RESTART. Press ENTER. 6. Use the UP and DOWN arrows to toggle between AUTO RESTART ON and AUTO RESTART OFF. Press ENTER to select. NOTE: See the Operating Guidelines section of this manual for a description of these functions. 7. Press MENU. Use ARROW keys to go to SELECT PROMPT. Press ENTER. 8. Use the UP and DOWN arrows to toggle between BASIC PROMPTS and ADVANCED PROMPTS. Press ENTER to select. NOTE: See the Operating Guidelines section of this manual for a description of these functions Robinair, SPX Corporation

7 Set-Up Instructions VACUUM PUMP INITIAL FILL 1. Press VACUUM to get to the VACUUM mode. Press START to go into VACUUM. Set Up Instructions NOTE: The vacuum pump is shipped without oil in the reservoir. Before starting the pump, oil must be added to the pump or damage may occur. 2. Close all manifold valves on the control panel. 3. Remove bolts holding the door closed and open the door. 4. Remove the black plastic plug from the fill port on the top of the vacuum pump. 5. Attach the oil fill tube to the 16 oz. bottle of vacuum pump oil provided in the accessory kit. IMPORTANT! For maximum performance, be sure to change the vacuum pump oil frequently. IMPORTANT! Be sure the pump is running when adding oil. 6. While the vacuum pump is running, add oil until it reaches the center of the sight glass. Press STOP. The vacuum pump is now filled to the proper level with oil. 7. Pour oil (approximately 12 oz.) into the fill port of the vacuum pump until the oil appears at the bottom of the sight glass. Press ENTER. 8. Replace the plug in the fill port. 9. Press STOP to exit. 1. Oil Fill Port 2. Sight Glass 3. Oil Drain 10. Close the door and replace the bolts holding the door shut INSTALLATION ROUTINE 1. Press MENU. Use the ARROW keys to go to the INSTALLATION ROUTINE. INST Press ENTER. The display toggles between CONNECT LS RXX HOSE TO SOURCE TANK and TURN ALL VALVES TO VACUUM/RECOVER AND PRESS START TO BEGIN. Follow the on-screen prompts. 3. Remove the service hoses from the accessory kit and remove the plugs from the hoses using a pair of pliers. 4. Attach the service hoses to the high and low side bulkheads on the rear of the unit. Attach the R-134a hoses to the left rear. Attach the R-12 hoses to the right rear. Attach the RED hoses to the bulkheads labeled HIGH and the BLUE hoses to the bulkheads labeled LOW K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 5

8 Operating Guidelines 5. Press START. The unit automatically evacuates the system for 5:00 minutes to remove any air from the external storage vessel (Ensure that all tank valves are open). IF THE SELECTOR SWITCH IS SET TO R-134A: 6. Connect the lowside service coupler to the source tank valve, using the adapter supplied with the unit, when the 5:00 minute evacuation is complete. Open the service coupler and turn manifold valves to RECOVER/VACUUM. IF THE SELECTOR SWITCH IS SET TO R-12: 7. When the 5:00 minutes evacuation is complete, connect the low side hoses the hose adapter supplied with the unit. Attach the adapter to the source tank. USING THE SELECTION MENU 1. Press MENU. The top line of the display reads LANGUAGE SELECTION. 2. Use the UP and DOWN arrows to scroll through the menu choices. The menu choices are (in order of appearance): 3. Press ENTER to make a choice from the menu. Press STOP to terminate any process. 1. LANGUAGE SELECT 2. CHANGE FILTER 3. FILTER WEIGHT 4. SELECT AUTO RESTART 5. MEASUREMENT UNITS 6. CHANGE VACUUM PUMP OIL 7. TANK FILL 8. VACUUM OIL TIME 9. INSTALLATION ROUTINE 10. SELECT PROMPTS 11. CHANGE DEFAULT (Password Protected) CHANGE FILTER The filter-drier removes acid, particulates and water from the refrigerant. Change the filter-drier after 150 pounds of refrigerant has been filtered. See the DRIER RECOVERED LBS. section on the following page as well as the Maintenance Section on page 20 for instructions Robinair, SPX Corporation

9 Operating Guidelines USING THE SELECTION MENU (continued) 4-a. TANK FILL (R-12 Users) NOTE: If using a refillable tank, place the tank upside down and connect the lowside service hose to the vapor valve. Set SELECTOR switch to R-12: 1. Connect the 6" yellow adapter to the end of the low side service hose. 2. Connect the low side service hose to the source tank and open valve. 3. Select TANK FILL from the Selection Menu. 4. Press ENTER. Then press START and the tank automatically refills. The unit stops when a sufficient amount of refrigerant has been transferred to the ESV- or - the source tank is empty. NOTE: Press STOP if you wish to stop fill before it completes. 5. Close the valve on the source tank. 6. Disconnect the 96" blue service hose from the adapter, then disconnect the 6" yellow adapter from the source tank. 7. Press STOP to exit. R-12 Low Side Service Hose Source Tank ESV INST K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 7

10 Operating Guidelines USING THE SELECTION MENU (continued) 4-b. TANK FILL (R-134a Users) NOTE: If using a refillable tank, place the tank upside down and connect the lowside service hose to the vapor valve. Set the SELECTOR switch to R-134a: 1. Connect the tank to quick-coupler adapter (supplied with the unit) to the low side service hose. 2. Connect the low side service hose to the source tank and open valve. 3. Select TANK FILL from the Selection Menu. 4. Press ENTER. Then press START and the tank automatically refills. The unit stops when a sufficient amount of refrigerant has been transferred to the ESV- or - the source tank is empty. NOTE: Press STOP if you wish to stop fill before it completes. 5. Close the valve on the source tank. 6. Disconnect the 96" blue service hose from the adapter, then disconnect the adapter from the source tank. 7. Press STOP to exit. VACUUM OIL TIME This feature displays the number of hours the vacuum pump has been used since the last oil change and needs reset after an oil change. Change the vacuum pump oil after every 10 hours of operation. See the Maintenance section on page 20 of this manual for instructions Robinair, SPX Corporation

11 Operating Guidelines USING THE SELECTION MENU (continued) FILTER WEIGHT This function is used to show the operator how many pounds of refrigerant have been recovered since the last filter change. 1. Select FILTER WEIGHT from the menu. Press ENTER. 2. The display shows amount of refrigerant recovered since last filter change. 3. If display reads greater than 300 lbs., go to MENU/CHANGE FILTER 4. Press STOP to exit. SELECT PROMPT Use the BASIC PROMPT option to receive step-by-step, on-screen prompting through any procedure. Use ADVANCED PROMPT once you know the procedure and no longer need the step-by-step routine. 1. Choose SELECT PROMPTS from the menu. Press ENTER. 2. Toggle between BASIC/ADVANCED using the ARROW keys. 3. Press ENTER to select the current choice. SELECT AUTO RESTART The AUTO RESTART ON option is used to automatically restart the unit if a pressure rise is detected by the unit during the five minute waiting period after recovering refrigerant. If AUTO RESTART OFF is selected, the operator must watch the gauges for a pressure rise and manually restart the recovery process if a pressure rise is detected. 1. Select AUTO RESTART. Press ENTER. 2. Use ARROW keys to toggle between the two options. 3. Press ENTER to select the current choice K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 9

12 Operating Guidelines USING THE SELECTION MENU (continued) MEASUREMENT UNITS 1. Select MEASUREMENT UNITS from the menu. Press ENTER. 2. Toggle between UNITS ENGLISH and UNITS METRIC using the ARROW keys. 3. Press ENTER to select the current choice. LANGUAGE SELECTION The operator can choose between English, Spanish, French, or German. 1. Scroll through the selection menu to LANGUAGE SELECTION and press ENTER. 2. Use the UP and DOWN arrows to scroll through the languages and then press ENTER to save the current choice. INSTALLATION ROUTINE and FIRST FILL The INSTALLATION ROUTINE is an automatic function that is used only for initial set-up. See the Initial Set-Up section of this manual for details Robinair, SPX Corporation

13 Operating Guidelines USING THE CONTROL PANEL The control panel has various components that control specific operating functions. MAIN POWER SWITCH Supplies electrical power to the control panel. DIGITAL DISPLAY Used on the visual interface between the operator and the machine. LOW SIDE MANIFOLD GAUGE Connects to an A/C system and shows the system s low side pressure. HIGH SIDE MANIFOLD GAUGE Connects to an A/C system and shows the system s high side pressure. LOW SIDE VALVE Controls the low side flow from the A/C system through the unit. It has two positions: 1) Vacuum/Recover, and 2) Closed. HIGH SIDE VALVE Controls the high side flow from the A/C system through the unit. It has three positions: 1) Vacuum/Recover, 2) Closed, 3) Oil Inject/Charge INST Diagram of Control Panel 1. Main Power Switch 2. Display 3. Low Side Gauge 4. High Side Gauge 5. High Side Valve 6. Low Side Valve 7. Keypad 8. Selector Switch K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 11

14 Operating Guidelines KEYPAD FUNCTIONS In addition to the number keys, the keypad contains special keys that accomplish specific operating functions. CHARGE Automatically charges the A/C system with the programmed amount of refrigerant. CLEAR Clears indicated data from the unit's memory. ENTER Enters programmed data into the unit s memory. MENU Enters the selection menu. RECOVER Activates the recovery sequence. START Begins a function. STOP Terminates a function. UP/DOWN ARROWS Used for scrolling through the menu items. VACUUM Activates the vacuum and automatic recycling sequence. Diagram of Keypad INST Robinair, SPX Corporation

15 Operating Instructions OPERATING TIPS Follow the recommended service procedure for the containment of R-12 and R-134a. The recovery compressor is not a vacuum pump. The compressor pulls the A/C system to a partial vacuum only. You must use the unit s vacuum cycle to remove moisture from the A/C system. We recommend a minimum 15-minute vacuum with more time as required by the system manufacturer. This unit is designed to be used with the manifold gauge set built into the control panel. It includes a 6 cfm (142 l/m) vacuum pump for fast, thorough evacuation. Be sure to change the vacuum pump oil after 10 hours of vacuum pump use. R-12 and R-134a systems require special oils. Refer to the A/C system manufacturer s service manuals for oil specifications. NOTE: The following operating instructions are written to be used with the BASIC PROMPTS mode of operation. It is recommended that the BASIC PROMPTS mode is used until the operator becomes very familiar with the operation of the unit. See the OPERATING GUIDELINES section of this manual for instructions on how to select between BASIC PROMPTS and ADVANCED PROMPTS K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 13

16 Operating Instructions RECOVERING REFRIGERANT WARNING Always wear safety goggles when working with refrigerant. Read and follow all warnings at the beginning of this manual before operating the unit. 1. Connect the power cord to the back of the unit and plug into the proper voltage outlet. 2. Turn on the MAIN POWER and empty the oil drain bottle located on the right hand side of the unit. 3. Press RECOVER. 4. If 300 or more pounds of refrigerant has been recovered since the last filterdrier change, the display reads REPLACE FILTER. 5. Connect the high and low side hoses to the A/C system service ports. For R-134a, open the coupler valves. 6. Place both High and Low Side manifold valves in the Recover/Vacuum position on the control panel. 7. If the system pressure is below 25 psi, the display reads LOW SYSTEM PRESSURE until the pressure increases or the START button is pressed. 8. If the unit has refrigerant in the low-side plumbing, it begins the clearing process and displays CLEARING. If you wish to skip the clearing operation or stop the clearing prematurely, press START. NOTE: An inaccurate recovery weight may result if the clearing operation is not completed. 9. When the system has recovered to a vacuum level of approximately 13 in. Hg., the compressor automatically shuts off. Manifold Gauges Manifold Gauges Valves Open Recover INST Diagram of Control Panel During Recovery 2000 Robinair, SPX Corporation

17 Operating Instructions 10. The unit then goes into automatic oil drain and the display reads OIL DRAINING. Oil draining can require up to 90 seconds to complete. 11. After the oil drain is complete, the display alternates between: RECOVERY COMPLETE CHECK OIL BOTTLE. RECOVERED XXX.XX lbs. RECOVERED XXX.X lbs. 12. Check the oil drain bottle and note the amount of oil that was removed from the A/C system. This is the amount of oil that must be charged into the A/C system after evacuation is complete. 13. To ensure complete recovery of refrigerant, wait 5 minutes and watch the manifold gauges for a rise in pressure above 0 in. Hg. A pressure rise may occur if there was freezing in the A/C system during recovery. If a rise occurs, press START to repeat the recovery process. Repeat as needed until the system pressure holds for two minutes, then press STOP. The AUTO RESTART ON option can be used to automatically restart the recycling process if the unit detects a pressure rise after five minutes. See the Selection MENU section for details. This process meets SAE Spec J Press STOP to exit. Recovery is now complete. You are now ready to make any repairs to the A/C system, if necessary, or advance to the Evacuation Process. Diagram of the Oil Injection System Oil Injector Bottle Oil Drain Bottle INST K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 15

18 Operating Instructions EVACUATING THE A/C SYSTEM WARNING Always wear safety goggles when working with refrigerant. Use only authorized refillable refrigerant tanks. Read and follow all warnings at the beginning of this manual before operating the unit. In addition to the number keys, the keypad contains special keys that accomplish specific operating functions. IMPORTANT! You should evacuate for at least 15 minutes to ensure adequate moisture and contaminant removal. IMPORTANT! If the vacuum pump has run for 10 or more hours without an oil change, the message VACUUM OIL TIME = Xhr. Xmin Xsec appears on the display. Change the pump oil following the procedures in the MAINTENANCE INSTRUCTIONS. 1. Connect the service hoses to the vehicle. R-134a users: Open the coupler valves. 2. Place both High and Low Side manifold valves in Recover/Vacuum. 3. Turn the unit on and press VACUUM. 4. If the vacuum pump has been run more than 10 hours since the last oil change, the display reads: VACUUM OIL TIME= X hr. Xmin. Xsec. Press STOP to change the vacuum pump oil or press START to continue. Instructions for changing the vacuum pump oil are located in the maintenance section of this manual. NOTE: Vacuum Pump oil should be changed after 10 hours of use to maintain maximum performance and endurance levels. 5. If the system being evacuated contains a pressure over 25 psi at any point during the evacuation, the display reads HIGH SYSTEM PRESSURE. This message indicates that the A/C system contains refrigerant. Press RECOVER to continue. After recovery is complete, return to Step 1 to evacuate the A/C system. 6. If the pressure is below 25 psi, the user is prompted to press START to VACUUM or press CHARGE to use the VACUUM-CHARGE (VAC-CHG) feature. If VACUUM is selected, the unit vacuums the system only and user interaction is required to enter the CHARGE mode. If the VACUUM- CHARGE feature is chosen, the unit automatically charges the system after evacuation is complete. Valves Open Vacuum 16 The Control Panel During Evacuation INST Robinair, SPX Corporation

19 Operating Instructions NOTE: If any oil was drained from the system during recovery, DO NOT use the VAC-CHG feature. The oil must be replenished into the A/C system, which is not possible when the VAC-CHG function is used. VACUUM 1. Press ENTER to accept the default evacuation time of 15:00 minutes or enter the desired vacuum time by using the number keys (To enter 10 minutes, press 1 and 10:00 should appear on the display. To enter 1 minute, press 0 then press 1, and 1:00 should appear on the display). 2. Press ENTER. The unit evacuates the A/C system and stops when the specified time has elapsed. 3. You are now ready to replenish the A/C system oil (if necessary) or to recharge the system with refrigerant. 4. Press STOP to exit. IMPORTANT! You should evacuate the A/C system for at least 15 minutes to ensure adequate moisture and contaminant removal. VAC-CHG 1. Press CHARGE to select the VAC-CHG feature. 2. Press START to charge the default amount of refrigerant (2.00lb) or use the number keys to enter the desired charge weight. Then press ENTER. 3. If the weight entered leaves less than 5 lbs. of refrigerant in the external storage vessel, the VAC-CHG process does not begin and the display reads LOW REFRIGERANT. At this point, refrigerant must be added to the external storage vessel. See the OPERATING GUIDELINES section of this manual for external storage vessel refill instructions and then return to Step 1 of EVACUATING THE A/C SYSTEM. 4. If the external storage vessel contains a sufficient amount of refrigerant, press ENTER to accept the default evacuation time of 15:00 minutes or enter the desired vacuum time by using the number keys. Then press ENTER. 5. The unit automatically charges the A/C system after the specified vacuum time has elapsed. 6. Advance to Step 6 of RECHARGING THE A/C SYSTEM in this manual to complete the charging process K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 17

20 Operating Instructions REPLENISHING A/C SYSTEM OIL Before charging the A/C system, you must replenish any oil removed from the A/C system during the recovery process. IMPORTANT! You can charge oil through either the low side or high side, or both, depending on the vehicle manufacturer s recommendation. Just open the appropriate manifold valve or valves. 1. Select the correct oil for the A/C system being serviced. Refer to the vehicle manufacturer's service manual. CAUTION! To prevent air from entering the A/C system, never let the oil level drop below the pick-up tube while charging or replenishing. 2. Adjust the O-ring around the oil injector bottle to the required oil charge level. For example, if the bottle's oil level is at 4 ounces and you need 1/2 ounce of oil to replenish the A/C system, place the o-ring at the 3 1/2 ounce level. 3. Install the bottle on the oil injection assembly on the back of the unit. CAUTION! Never open the oil injection valve while there is positive pressure in the A/C system. This action could blow oil back through the bottle vent. 4. Place the Low Side valve in the Closed position. Place the High Side valve in the Oil Inject/Charge position. 5. Turn the oil injection valve at the top of the bottle and watch the level of oil being drawn into the A/C system. This process takes only seconds watch carefully! 6. Turn OFF the valve when the required oil charge has been pulled into the system. Oil Injector Bottle Closed Oil Inject/Charge Oil Drain Bottle INST 0770 INST Robinair, SPX Corporation

21 Operating Instructions RECHARGING THE A/C SYSTEM WARNING Always wear safety goggles when working with refrigerant. Use only authorized refillable refrigerant tanks. Disconnect hoses with extreme caution! All hoses may contain liquid refrigerant under pressure. Read and follow all warnings at the beginning of this manual before operating the unit. 1. Press CHARGE. 2. Accept either the default weight by pressing START or type in a weight with the number keys and press START (For example, to program 3 lbs, press 3 and 3.00 lbs will appear on the display. To program 3.25 lbs, press 3-2-5, in that order, and 3.25 lbs will appear on the display). 3. If the weight entered will leave less than 5 lbs. of refrigerant in the refrigerant tank, the charge function will not start and the display will read: LOW REFRIGERANT Refrigerant XX.XX lbs. See the Operating Guidelines section of the manual for refill instructions. 4. Close the Low Side valve. Place the High Side valve in the Oil Inject/Charge position (Note: Use the valves corresponding with the refrigerant you are working with). 5. Upon entering a valid charge weight, the display shows: CHARGE MODE Closed AMT. CHARGED XX.XX lbs. Press START to continue. 6. The display will say "Charge complete. Amt. charged XX.XX". 7. Close the high and low side coupler valves and remove the service hoses from the A/C system. 8. Turn off the MAIN POWER switch. The A/C system is now ready for use. Oil Inject/Charge Note: To add less than 1 pound of refrigerant, such as 0.25, press 0-2-5, in that order. IMPORTANT! You should evacuate the A/C system for at least 15 minutes for adequate moisture and contaminant removal. INST 0770 CORRECTING AN INCOMPLETE CHARGE On ocassions the AMT. CHARGED will not finish. The reason for this is that the pressures in the ESV and the A/C system have equaled. To finish the charge, you should: 1. Turn high side valve on the control panel to the closed position. 2. Turn low side valve on the control panel to recover/vacuum position. 3. Start the vehicle and turn on the A/C. 4. The remainder of the charge will be pulled into the A/C system and display will read CHARGE COMPLETE K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 19

22 Maintenance Instructions REPLACING THE FILTER-DRIER Order part #34724 for a replacement filter-drier. The filterdrier on this unit is designed to trap acid and particulates and is formulated to remove water from the refrigerant. You must change the filter-drier to assure adequate moisture and contaminant removal. Typically, you can recycle up to 300 pounds (136 kilograms) of refrigerant between filter changes. CAUTION! For best results, use Robinair filter-driers (part no ). All performance tests and claims are based on using this specially-blended filter-drier. Use of another may affect performance results. Filter Filter-Drier INST0477 Filter 1. Press MENU. 2. Scroll through the menu to CHANGE FILTER and press ENTER. Display reads: RXX Filter Weight X.XX lbs. 3. Press START to begin. 4. Wait for the unit to self clear. 5. When clearing is complete, the display reads DISCONNECT POWER. Replace RXX filter. 6. Turn off the main power and unplug the machine. 7. Open the unit door and replace the old filter with the new filter. 8. Close the unit door, plug in the machine, and turn on the Main Power. 9. Close the door to the unit. 10. The filter change is now complete. Location of the Filter-Drier INST Robinair, SPX Corporation

23 CHANGING THE VACUUM PUMP OIL For maximum vacuum pump performance, change the vacuum pump oil every 10 hours of operation. 1. Press MENU. 2. Use the ARROW keys to select CHANGE VAC PUMP OIL. 3. Press ENTER. NOTE: Do not connect the service hoses to a vehicle. 4. Ensure that the high side and low side manifold valves are closed and press START. 5. Screen displays OIL CHANGE. 6. Allow the vacuum pump to run until it automatically stops (2 minutes). 7. Remove the black plastic plug on the oil fill port of the vacuum pump. 8. Remove the oil drain cap from the vacuum pump and drain the oil into a suitable container for proper disposal. 9. Replace the oil drain cap and press START. Maintenance Instructions 10. Screen now toggles between ADD 5 oz. OF OIL TO VACUUM PUMP and PRESS START TO CONTINUE. 11. Attach the flexible tube and cap to the oil bottle and pour five ounces of vacuum pump oil into the fill port. 12. Press START and while the vacuum pump is running, slowly add oil until the level is even with the line on the reservoir's sight glass. 13. Press STOP and replace the black plastic plug on the fill port. 14. The unit is now ready to operate K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 21

24 Maintenance Instructions Diagram of Vacuum Pump INST Oil Filler Tube 2. Pump Exhaust 3. Oil Fill Port 4. Sight Glass 5. Oil Drain Fitting 6. Inlet INST Oil Fill Port 2. Sight Glass 3. Oil Drain IMPORTANT! Inspect the unit periodically for leaks. The manufacturer does not reimburse for lost refrigerant. CHECKING FOR LEAKS Every three months, or as specified by local or state laws, you should check the unit for leaks. 1. Turn off the MAIN POWER switch, and disconnect the power cord from the outlet. 2. Open door. 3. Use a leak detector to probe all connections for refrigerant leaks. Tighten fittings if a leak is indicated. 4. Close door Robinair, SPX Corporation

25 Maintenance Instructions ELECTRICAL PROTECTION If the circuit breaker trips, all power to the unit is lost. Press the circuit breaker button to reset. The circuit breaker is located near the fuse on the back of the unit. GENERAL MAINTENANCE 1. On a regular basis, wipe off the unit with a clean cloth to remove grease, dust or other dirt. 2. Periodically check the internal components for leaks over time, fittings can loosen as the unit is moved. Open the unit door panel and trace lines with a leak detector. Also, check connections on the back of the unit. Tighten any loose fittings or connections you may find K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 23

26 Replacement Parts The following is a list of replacement parts and accessories you may need to service or maintain your unit. We suggest you keep several filter-driers on hand so you will always be able to change them and complete any recycling job that is in progress. Premium High Vacuum Pump Oil is also available in handy quart containers or in convenient gallon containers: Quart (shipped 12 quarts per case) Gallon (shipped 4 gallons per case) Because of ongoing product improvements, we reserve the right to change design, specifications, and materials without notice Robinair, SPX Corporation

27 Replacement Parts List K Replacement Parts R-12 R-134a Replacement Replacement Component Part Number Part Number 96" Red Hose 68396A " Blue Hose 68296A Fan RA17516 RA19409 Filter-Drier Compressor RA19735 RA19735 Vacuum Pump RA15425 RA15425 High Pressure Switch RA19427 RA19427 Main Power Switch RA19344 RA19343 Vacuum Switch RA19428 RA19428 Pump Protection Switch RA19429 RA19429 Automatic Expansion Valve RA19592 RA19592 Scale Assembly RA19603 RA19603 Main Circuit Board RA19594 RA19740 High Side Gauge RA19742 RA19613 Low Side Gauge RA19741 RA19614 Low Side Coupler N/A 18190A High Side Coupler N/A 18191A Automatic Air Purge RA19476 RA19595 Relays RA17459 RA17459 Transformer RA19596 RA19596 Solenoid Rebuild Kit RA19258 RA19258 UL Circuit RA19673 RA K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 25

28 Replacement Parts List K Replacement Parts Component R-12 R-134a Replacement Replacement Part Number Part Number 96" Red Hose 68396A " Blue Hose 68296A Fan RA17516 RA19409 Filter-Drier Compressor RA19736 RA19736 Vacuum Pump RA15428 RA15428 High Pressure Switch RA19427 RA19427 Main Power Switch RA19344 RA19343 Vacuum Switch RA19428 RA19428 Pump Protection Switch RA19429 RA19429 Automatic Expansion Valve RA19592 RA19592 Scale Assembly RA19603 RA19603 Main Circuit Board RA19740 RA19740 High Side Gauge RA19742 RA19613 Low Side Gauge RA19741 RA19614 Low Side Coupler N/A 18190A High Side Coupler N/A 18191A Automatic Air Purge RA19476 RA19595 Relays RA17324 RA17324 Transformer RA19596 RA19596 Solenoid Rebuild Kit RA19258 RA19258 UL Circuit RA19673 RA Robinair, SPX Corporation

29 INST 0717 Flow Diagram K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 27

30 Wiring Diagram Inst Robinair, SPX Corporation

31 Limited Warranty This product is warranted to be free from defects in workmanship, materials and components for a period of one year from date of purchase. All parts and labor required to repair defective products covered under the warranty will be at no charge. The following restrictions apply: 1. The limited warranty applies to the original purchaser only. 2. The warranty applies to the product in normal usage situations only, as described in the Operating Manual. The product must also be serviced and maintained as specified. 3. If the product fails, it will be repaired or replaced at the option of the manufacturer. 4. Transportation charges for warranty service will be reimbursed by the factory upon verification of the warranty claim and submission of a freight bill for normal ground service. Approval from Robinair must be obtained prior to shipping to either an authorized service center or the factory. 5. Warranty service claims are subject to factory inspection for product defect(s). 6. Robinair shall not be responsible for any additional costs associated with a product failure including, but not limited to, loss of work time, loss of refrigerant, and unauthorized shipping and/or labor charges. 7. All warranty service claims must be made within the specified warranty period. Proof-of-purchase date must be supplied to the manufacturer. 8. Use of Robinair recovery/recycling equipment with unauthorized refrigerants will void our warranty. Authorized refrigerants are listed on the equipment or are available through our Technical Service Department. This Limited Warranty does not apply if: The product, or product part, is broken by accident. The product is misused, tampered with, or modified. The product is used for recovering or recycling any substance other than the specified refrigerant type K/348012K Cool-Tech Recovery/Recycling/Recharging Unit 29

32 CONVERSION TABLE OZ. LBS lb. Visit our web site at or call our Toll-Free Technical Support Line at in the continental U.S. or Canada. In all other locations, contact your local distributor. To help us serve you better, please be prepared to provide the model number, serial number, and date of purchase. To validate your warranty, you must complete the warranty card attached to your unit and return it within ten days from date of purchase. NATIONWIDE NETWORK OF AUTHORIZED SERVICE CENTERS If your unit needs repairs or replacement parts, you should contact the service center in your area. For help in locating a service center, call the toll free technical support line. Due to ongoing product improvements, we reserve the right to change design, specifications and materials without notice. The K and K are designed to meet all applicable agency certifications including Underwriter's Laboratories, Inc., SAE Standards and CUL. Proper maintenance of this equipment will provide accurate A/C service for many years. Certain state and local jurisdictions dictate that using this equipment to sell refrigerant by weight may not be permitted. We recommend charging for any A/C service by the job performed. This weight scale provides a means of metering the amount of refrigerant needed for optimum A/C system performance as recommended by OEM manufacturers. SPX ROBINAIR SPX Corporation 1224 Robinair Way, Box 193 Montpelier, OH Phone: Fax: Web site: (Rev. 05/00) K/348012K Operating Manual Printed In USA